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Optimizing Oilfield Production with Intelligent Artificial Lift Solutions
Alexander Mendoza
CEO & President
BCP Group
Juan Camilo Mosquera
R&D Automation Engineer
BCP Group
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Next developments
Innovation and technology as a solution for each challenge
Automation equipment necessary to make intelligent solutions
Conventional Well Pads / Challenges
BCP Group as holding company
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BCP Group Worldwide
United States Canada Mexico
Venezuela
Colombia Ecuador
Peru
Brazil
Argentina
BCPVEN: Created in 2002 to tend to
Venezuelan market with two factories:
west Venezuela (CIBOC), Venezuelan
headquarters, financial and R&D
department. East Venezuela (CIBOR),
WOS factory, high tech. bench test
and Orinoco belt services base
SLACOL: Created in 2005 to tend to
markets for Colombia, Ecuador and
Peru, with a factory located in Bogotá
and special services facilities in Pacific
Rubiales oil field
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BCP Group Worldwide
BCPBRA: Created in 2012 to tend to
Brazilian market and create global solutions in
Oil & Gas applications with NETZSCH.
Factory located in Pomerode, Santa Catarina,
and building the CITE do Brasil, “Complexo
Industrial e Tecnologico do Brasil”
ESP International: Created in 2005 to develop
the North American and Caribbean market,
also responsible for developing corporate
policies of each company belonging to BCP
Group companies. With Projection of new
facilities in Houston
United States Canada Mexico
Venezuela
Colombia Ecuador
Peru
Brazil
Argentina
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Next developments
Innovation and technology as a solution for each challenge
Automation equipment necessary to make intelligent solutions
Traditional Well pads / Challenges
BCP Group as holding company
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Key Challenges for production
PRODUCTION OPTIMIZATION
TECHNOLOGY STANDARDIZATION
INCREASE RUNLIFE
ENERGY QUALITY
FACILITIES INFRASTRUCTURE
PRODUCTION
CHALLENGES
• Optimization algorithms (Well, Well pad & Oilfield) • Production measurements
• Massification of ALS technology plant wide • Equipment supply on time (Stock)
• Quick diagnostics for failures • Traceability of process variables
• Electrical protection of assets: surface and downhole • Control algorithms to optimize energy consumption
• Low commissioning time
• Easy integration with subsystems on well pad
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Well Pads (Downhole)
PCP Control
(Tubular, insertable,
Evenwall.)
Intelligent torque
control for rods
Different types
of drive heads
Backspin control
Interaction with
different brands of
downhole sensors
Motor control
(Induction, PMM)
Electrical
Submersible
Pump
Tubing head
temperature
Tubing head
pressure
ESP COMPLETION
PCP COMPLETION
G.E Smartguard SLB UniConn G.E Scout Zenith Phoenix Centinel
General
Electric Schlumberger Baker Hughes Novomet Borets Alkhorayef
Netzsch TDA Weatherford
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Well Pads (Surface)
PCP WELLHEAD ESP WELLHEADS
SEVERAL PROVIDERS FOR DRIVES
STEP UP TRANSFORMERS FOR ESP
Wellhead Wireless hart
Instrumentation
Manifold Wireless hart
Instrumentation
Serial Comm. For each drive
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Production Challenges Working with Traditional Well Pads
All disciplines involved in the oil production process need to be synergic to be optimal
Electrical Engineering
Artificial lift Engineering
Civil Engineering
Petroleum Engineering / Artificial lift (Completion) / Optimization
Automation and Control Engineering
Production Management
Artificial lift systems must be designed with innovative features that allow the customer to
measure the production and maintain their assets
The Artificial lift process needs to be optimal: from the construction of facilities to the equipment operation, monitoring, control and optimization.
“The Artificial lift process needs to be automated to provide intelligent online solutions to optimize oilfields”
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Next developments
Innovation and technology as a solution for each challenge
Automation equipment necessary to make intelligent solutions
Traditional Well Pads / Challenges
BCP Group as holding company
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Rockwell Automation Technology in BCP Group’s Solutions
BCP Group as standard,
demands the best technology
that allows for growth
The stability of Rockwell
Automation products,
integrated with our dedicated
engineering, help us create
innovative solutions
The simplicity of integration is
valuable for our developments
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The Ideal Components to Develop Integrated Solutions Plant Wide
We realized that the capability of control systems solved integrity needs
the customer required. Power electronics, Artificial lift knowledge, control
strategies, automation and the simplicity of a friendly, operative interface
were our strengths
ControlLogix® technology
(More than 15 high-level O&G
algorithms in our applications)
VFD technology
(Drives solutions for a variety of
power ratings according to the
Artificial lift system)
Power quality
(Online electrical analysis to help
ensure equipment’s performance)
Interface
(Intuitive operation developments.
Functional operative interface)
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Selection Criteria
Our customer implemented the PlantPAx® concept plant wide, and our technology was
exactly the solution to grow up with them in this process
Team work made us a distinctive company for them, because the market was just
providing them drives. We innovated with the automation technology to supply the perfect
Artificial lift controller and give them what they most needed: Optimization applications.
When Rockwell Automation realized its vision of the integrated architecture, we knew we were capable of developing competitive
solutions
“Rockwell Automation provided us all equipment necessary to make the equipment they needed in an efficient way and on time”
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Agenda
Next developments
Innovation and technology as a solution for all challenges
Automation equipment necessary to make intelligent solutions
Traditional Well pads / Challenges
BCP Group as holding company
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Extensive knowledge in Artificial lift systems
Extensive knowledge in Artificial lift systems
The best control technology and power
systems
A leader in control technology and power
systems
The synergic integration of both created the CILA2S
CILA2S: Intelligent Controller for Artificial lift, Sub/surface
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Pump speed control (RPM, HZ, SPM)
Surface instrumentation Control and monitoring
Monitor complete surface and down hole variables to
feed the optimization, control and protection
algorithm
Total Integration with surface instrumentation and down hole sensors
CILA2S: Intelligent Controller for Artificial lift, Sub/surface
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Previous Installed Base
“An experience of more than 1500
CILA2S installed”
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CILA2S Architecture
POWER SUPPLY
(480V AC)
LOAD (SUT/PUMP)
(PUMP)
SINE WAVE FILTER
HARMONICS FILTER
SPD FUSES BREAKER
0 to 480VAC 0 to 300Hz
PROTECTION MODULE POWER QUALITY VSD MODULE
CONTROL MODULE
ETHERNET TCP / IP
DOWNHOLE SENSOR
SCADA POWER MONITOR
MODBUS TCP IP
CONTROLLER
FIELD INSTRUMENTATION
HART I/O ANA- DIG I/O
HMI MODBUS RTU
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Applications Designed for Artificial lift Methods
Online operative data Multilanguage applications
Power quality VSD control Optimization Algorithms
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Well Diagnostics That Are Based in Graph Charts
Nomographic chart. Digital circular chart
Dinagraph chart Well productivity chart
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CILA2S as the Solution for a Standalone Artificial Lift System
The CILA2S as an integrator of engineering multidiscipline is designed for different
Artificial lift methods according to the customer fields
ESP: Electrical submersible pumps
PCP: Progressive cavity pumping
BP: Beam pump
MPP: Multiphase pumping
MSP: Multiscrew pumping
The constant developments in optimization applications, applied automation engineering and the “know how” in Artificial lift methods, brought the solution to an experienced customer in the Oil & Gas area
“From 2010 to present time, 302 CILA2S have been delivered to this
customer, and we continue manufacture under new contracts”
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WOS: Well Optimization System
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WOS: Well Optimization System
Clean agent
extinction system Indoor downhole
surface panel
mount for each well Field
Instrumentation
access
Well controller
systems for different
Artificial lift methods
(ESP, PCP, BP, MPP, MSP)
Access control system
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WOS: Well Optimization System
Power distribution
center
Controlled
environment
air conditioning
Central control
system
Emergency shutdown
system Energy quality systems
(Harmonics / Sine wave Filters)
(Electrical protections)
Auxiliary services
center
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Central Control System
Online production measurement
Centralized operative data Field instrumentation
WOS Electrical consumption
Intelligent Well Optimization Control
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WOS Control Architecture
Well control system
(Cila2s concept)
Well control system #1 Well control system #2 Well control system #N
. . . Ascii
Access control system
Emergency shutdown system
Ethernet TCP / IP
Central control system
SCADA connectivity
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Previous Installed Base
“An experience of more than 8
WOS installed”
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WOS Technology to Optimize Production
Implementation benefits of WOS solution:
One solution for complete well pad control with all equipment integrated
Manufacture and start-up time is less than 45 days
Optimum analysis of all operative variables through historical data
Drives and control systems installed under a clean, controlled environment
High reliability and speed in communications to measure production
Security compliance with the access control system
Single contract for maintenance
Easy transport from one well pad to another
Costs and construction time to develop a well pad decrease
The centralized concept of the WOS technology allows the customer to optimize the production, optimizing the well pad construction
“From year 2010 to present time, 77 WOS were delivered to the customer,
with more than 400 single well controller systems”
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WOS SCADA
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WOS Scada as a Solution for the Field
The well optimization concept
was taken to the whole field
optimization
A Scada that connected more
than 1100 Wells across the
customer’s field were now
capable to be optimized just
from an operations control
center
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Field Navigation and Quick Information
Tree view to search and explore the desired well
Field map with well pad immediate status
Navigation menu with easy access to most important displays Scada developed
in FactoryTalk® View
PlantPAx ® guidelines followed
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Easy Access to Well Status
Well pad summary visualization
Direct link to each well information detail
Well status view of the complete field, based in color codes
Direct link to an alarmed well with just one click
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All Information of the Well in Just One Display
• Remote control of the well: Start and stop commands • Speed increments and protection configurations
• Drive status • Spin direction • Speed reference
• Sub/surface operative data
• Alarms and events
• Electrical data • Tree view and
browsing for well pads/wells
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Remote Online FIELD Optimization
• Downhole information + Well Characterization
• Constant protection of the wellbore
• Constant protection of motor/pump
• Speed increments/decrements suggestions, based on CILA2S’ intelligent well
control analysis
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The Solution for the Intelligent Oilfield
The SCADA was developed under PlantPAx® guidelines to adhere to customer standards
The advantage of our “know how” in oil production allowed us to develop a dedicated
SCADA for well production
The information in SCADA has multidisciplinary data to demonstrate smart integration of
operations and prove that production is the daily matter in these oilfields
The WOS SCADA solution collects online information from all standalone solutions, WOS well pads, and brings the optimization to the hand of customer’s Optimization Engineers gaining time to increment production
“The Scada brings efficiency to the oilfield, optimizing not just on site but in
operations control centers. The connectivity and dedicated information was
a sure help for our customer”
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Next developments
Innovation and technology as a solution for each challenge
Automation equipment necessary to make intelligent solutions
Traditional Well pads / Challenges
BCP Group as holding company
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Knowledge through
Optimization tools
Optimization Coaching & Machine Learning
Interactivity of the machine analysis with Optimization
Engineering
Continuous coaching based in the machine
learning
Advanced Process Control Fuzzy Logic
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Questions
Alexander Mendoza
CEO & President
BCP Group
Juan Camilo Mosquera
R&D Automation Engineer
BCP Group
www.bcpgrp.com